Deform2DlabsHT PDF

1.
GEOMETRY MANIPULATION - XYR FORMAT
1.1. Creating a New Problem
1.2. Setting Simulation Controls
1.3. Creating a New Object
1.4. Display Manipulation
1.5. Point Selection
1.6. Other DISPLAY Window Buttons
1.7. Saving the Problem
1.8. Exiting DEFORM-2D

DEFORM-HT Labs
1. Geometry Manipulation - XYR Format

On a unix machine, type DEFORM2 to open DEFORM-2D. On a Windows machine, go to
the button and select DEFORM-2D from the menu. The DEFORM-2D MAIN window
will appear, as shown below.
Create a new problem by either selecting File New Problem or by clicking the New Problem
icon. The PROBLEM SETUP window will appear. Accept the default setting of opening a
new problem using the DEFORM-2D pre-processor by clicking .
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Click to define the location of the new problem Under DEFORM Problem
directory.
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In the field for Problem Name, call the problem Mesh and click .
The DEFORM-2D Pre-processor will open. The Pre-processor is divided into several distinct
sections - namely the DISPLAY window, the Object Tree and Object Data. There is also a row
of icons along the top of the screen. These icons will be described as they are encountered in the
labs. The most important of the icons are the ones located at the top right. Due to their
importance, a brief description of each is given:
Icon Function Description

Simulation Control All simulation controls and stopping criteria are defined
within this menu.
Material Material properties are defined in this menu.
Object Positioning Objects are positioned using these controls.
Inter-Object Relationships among the objects are defined here.
Database Generation Once all pre-processing is complete, this menu generates
the database that is required for solving.
Exit This button exits the Pre-Processor and returns the user
to the MAIN window.
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Object Tree
Display window
Object Data
Click on the icon to open the SIMULATION CONTROL window. Change the Simulation
Title to Mesh. Make sure that the Units are set to English, Deformation is activated (has a
checkmark next to it), and Geometry is set to Axisymmetric. Click the button
when finished.
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Add an object to the problem by clicking the Insert object icon that is under the Object Tree.
Change the Object Name from Object 1 to Billet and then click the button. Set the
Object Type to Plastic.
In DEFORM-2D, an objects surface definition is referred to as its geometry. An objects

geometry can either be created within DEFORM or it can be imported as a .dxf or .igs file. In
this lab, the geometry of the billet will be created within DEFORM.
Click and then click the Edit tab. A blank table will appear. Enter the following
XYR coordinates in the table and then click on the button.
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You should now see the geometry in the DISPLAY window. Click the to see if
there are any problems with the geometry.
Use the default checking parameters and click . A message saying "Geometry is
legal" will appear.
1.4. Display Manipulation
Functions that manipulate the DISPLAY window (such as Pan, Zoom, Magnify, and Rotate) can
be activated using icons at the top of the Pre-processor window. These functions also have easy
keyboard/mouse combination hotkeys that allow the user to quickly perform these functions
without any excessive button clicking. Once you have read about these functions, feel free to use
them to manipulate the view of the Billet in the DISPLAY window.
Display Icons

Pan The objects in the DISPLAY window can be
dynamically panned up, down, left, or right by moving
the mouse while holding the left mouse button.
(Shortcut: Shift + Left Mouse Button)
Zoom The DISPLAY window can be dynamically zoomed in

or out by holding the left mouse button and moving
the mouse up or down.
(Shortcut: Alt + Left Mouse Button)
Magnify A portion of the DISPLAY window can to be magnified

by clicking and holding the left mouse button at one
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corner of the zoom box and dragging the cursor to create

a window encompassing the zoom area.
(Shortcut: Ctrl + Alt + Left Mouse Button)
1.5. Point Selection

Any point on an object in the DISPLAY window can be selected to obtain the corresponding data
for that point. Also, distances can be measured either between two points on one object or
between two points on different objects.
Point Selection Icons

Measure Distances between any two points can be measured by
clicking the first point and then clicking the second
point. The measuring line will remain on the screen until
the Refresh button is clicked.
Select This is the default display mode and is used to select and
get information about nodes and element faces. This is
also the mode used when measuring.
1.6. Other DISPLAY Window Icons

The following icons are also used when viewing objects in the DISPLAY window:

View shaded objects All objects are shown shaded without a mesh.
View mesh only All objects are shown unshaded with a mesh.
View shaded mesh All objects are shown shaded with a mesh.
View surface patch Only the feature lines of the objects are shown
Refresh Refreshes the DISPLAY window and clears the screen

of any previous measuring lines
View Fit Fits all objects into the DISPLAY window

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View Back Reverts back to the last view used
Capture Image Captures the DISPLAY window and saves it to a file
Print Captures the DISPLAY window and sends it to the

printer

This is a good point to save your data. To save the data to a keyword file, either select File
Save or click the Save icon. The data will be saved in the file Mesh.KEY.
Exit the Pre-processor by clicking the Exit icon.
If you are not continuing on to Lab 2, you can exit DEFORM-2D by selecting either File Quit
or the button. When asked whether you want to quit, click .
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2. GEOMETRY INPUT - IGES FILES
2.3. Creating New Objects

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2. Geometry Input - IGES Files

will appear.
Create a new problem by clicking the icon. Accept the default setting of opening a new
problem using the DEFORM-2D Pre-processor by clicking . Click to

define the location of the new problem 'Under DEFORM Problem directory'.
In the field for Problem Name, call the problem Spike and click . The DEFORM-
2D Pre-processor will open.
Title to Spike Forging. Make sure that the Units are set to English, Deformation is activated
and Geometry is set to Axisymmetric. Click the button when finished.
Use the icon to add three objects to the Object Tree.
2.3.1. Object 1
Change the Object Name to Billet and set the Object Type to Plastic. The geometry for this
billet is located in an .IGS file. Click the button and then click .
All geometry files are located in the DEFORM2D\V*_*\Labs directory (where V*_* is the
currently installed version such as V8_0). Switch to this directory and import Spike_Billet.IGS
by highlighting it and then clicking . The imported geometry should appear in the
DISPLAY window. By default, the option should be checkmarked and

the arrows defining the orientation of the geometry should be visible.
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The points defining this imported geometry can be viewed/edited by clicking the Edit tab. When
.IGS files are loaded, the data gets imported into DEFORM in Line-Arc format, which defines
the geometry in terms of lines and arcs. To view the XYR format of the geometry, click the
XYR Geo Format button.
Whenever a geometry is imported, it should be checked. Click the button and
then the button. This not only fixes any problems with the geometry but also
corrects the orientation of the geometry if needed. Notice how checking this geometry changed
the orientation from clockwise to counter-clockwise, which is correct.
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2.3.2. Object 2
Highlight Object 2 in the Object Tree, click the button and change the Object Name to
Top Die. Click the button and then the file Spike_TopDie.IGS.
the geometry to make sure it is OK.
2.3.3. Object 3
Highlight Object 3 in the Object Tree, click the button and change the Object Name to
Bottom Die. Click the button and then the file Spike_BottomDie.IGS.
the geometry to make sure it is OK.
Save your data to a keyword file by clicking the Save icon. The data will be saved in the file
Spike.KEY.
If you are not continuing on to Lab 3, you can exit DEFORM-2D by clicking the button in
the MAIN window. When asked whether you want to quit, click .
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3. GEOMETRY INPUT - GEOMETRY CORRECTION

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3. Geometry Input - Geometry Correction

will appear.
Create a new problem by clicking the icon. Accept the default setting of opening a new
problem using the DEFORM-2D Pre-processor by clicking . Click to

define the location of the new problem 'Under DEFORM Problem directory'.
In the field for Problem Name, call the problem Junk and click . The DEFORM-
2D Pre-processor will open.
Title to Junk. Make sure that the Units are set to English, Deformation is activated and
Geometry is set to Axisymmetric. Click the button when finished.
Use the icon to add an object to the Object Tree. Change the Object Name to Billet and set
the Object Type to Plastic. Click and then click the Edit tab. A blank table will
appear. Enter the following XYR coordinates in the table and then click on the
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Using the Magnify icon, zoom in on the intersection between the two arcs. You can see that
the endpoints of the two arcs do not meet correctly.
Click the button and then . The message "Geometry has been
corrected" should pop up.
The default correction settings worked well for this geometry, creating a small line between the
two arcs.
Save your data to a keyword file by clicking the Save icon. The data will be saved in the file
Junk.KEY.
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4. UNIFORM MESH GENERATION 4-1

4.1. Creating a New Problem 4-1
4.2. Importing an IGES Geometry 4-1
4.3. Generating a Uniform Mesh Density 4-2
4.4. User-Defined Mesh Density. 4-4
4.5. Saving the Problem 4-5
4.6. Exiting DEFORM 4-5

DEFORM-HT Labs
Problem Summary:
The intent of the lab is to show the user how to import an IGES file geometry into
DEFORMTM and how to define a mesh for the geometry. There are two different
methods for defining the mesh of the object, system defined and user defined. Two
examples of each type are shown below in the example of a cross-section of a ring.
Notice the differences between Figures 4.1 and 4.2.
Figure 4.1: System Defined Definition (Uniform Mesh)
Figure 4.2:User Defined Defintion (Note the greater density at the object
boundary).
DEFORM-HT Labs
4. Uniform Mesh Generation

Make sure that you are in the MAIN DEFORM window, if you are not in the
MAIN DEFORM window, start DEFORM. Click on the Up directory icon
until you are in your main labs directory. Create a directory by clicking on
the Create a New directory icon . When prompted enter the directory name
RING. In the Problem ID text box, change the Problem ID to RING. Once this
has been done, you are ready to enter the Pre-Processor to define your simulation
data. Click on the Pre-Processor button. The DEFORM-2D Pre-Processor
should appear.
Checklist
1. User should be in RING directory
2. Named Problem ID RING
3. Entered the Pre-Processor
4.2. Importing an IGES Geometry
We need to define the workpiece for the simulation. Click on the Objects button
in the CONTROL window. The OBJECTS window will appear. In the
OBJECTS window the user can specify any data that applies to the activated
object. Object #1 is created by default so there is no need to create a new object.
Change the Object Name of object 1 to RING, and change the Object Type to
ELA-PLA (elasto-plastic). Now click on the Geometry button to define the
geometry of the selected object. The GEOMETRY window will appear with a
blank table. You will be reading the geometry in from an IGES file so click on
the Load IGES File button in the GEOMETRY window. The IGES FILE
SELECTION window will appear. Locate the IGES file RING.IGS under the
Files listing and double click the cursor on the filename. Now click on the Ok
button to read in the IGES file. The IGES FILE INPUT window will appear.
This contains a listing of information on the IGES file. The default settings
should be fine, so click on the Ok button. The Imported IGES geometry will
now appear in the DISPLAY window and the IGES window will appear listing
the number of curves, entities and points. Click on any line of the geometry.
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The object should change colors from white to yellow. Click on the Ok button in
the IGES TRANSLATOR window to import the selected curve. You will be
prompted whether you want to check the geometry of the imported object, click
on Yes. A window stating that the geometry is legal will appear, click on the Ok
button. The table in the GEOMETRY window should now contain a list of
points making up the geometry.
Important Note:
By looking at the direction of the lines of the disk, one can see that the lines
follow a clockwise direction. It is critical for the user to always make sure
that the geometrys used are counterclockwise in direction. DEFORMTM
uses the orientation of the lines to determine the outside and the inside of
objects. By defining the DISK as counterclockwise, DEFORMTM
understands the object to be filled with material and the outside to be empty
space. In the case where the user was to have clockwise geometry, clicking
on the Reverse Geometry Icon can reverse it. Improper orientation is often
the problem when the mesh generator is incapable of meshing an object or
when the user has a problem positioning the geometry by an interference
method. It should be noted that the check geometry feature doesnt check for
correct orientation.
Reverse the Geometry by clicking the Reverse Geometry Icon. Click on the Ok
button in the GEOMETRY window. The DISPLAY window should now display
the geometry you have created, a hollow disk.
Checklist
1. Titled Object #1 RING
2. Set RING type to Ela-Pla (elasto-plastic)
3. Loaded RING.IGS
4. Reversed geometry of RING
4.3. Generating a Uniform Mesh Density

In order to generate a mesh for the object, click on the Mesh button and the
MESHING / REMESHING window will appear as shown in Figure 4.3.
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Figure 4.3 - Meshing / Remeshing window
The selected object will appear highlighted in red in the Display window. Set
the Number of Mesh Elements (MGNELM) to 600 elements. Now set the
Maximum Size Ratio (MGSIZR) to 1. This action will create a uniform the
mesh.
Definition: Maximum Size Ratio (MGNELM)

Maximum Size Ratio is the ratio between the smallest element edge
length to the largest element edge length. Thus, if this value is set to
unity, the mesh will be uniform or nearly uniform.
Definition: Number of Thickness Elements (MGTELM)
The Number of Thickness Elements is a value that defines the minimum

number of elements that the mesh generator will try to allocate in the
thickness direction at the thinnest sections of the object such as ribs or
fins.
Now click on the Generate Mesh button to generate the mesh. To create a new
mesh, just change the mesh parameters and click on the generate mesh button.
Try this by setting the Number of Mesh Elements to 200, and click on the
Generate Mesh button. A new mesh should appear in the DISPLAY window.
You may continue to change the Number of Mesh Elements, Maximum Size
Ratio, and Number of Thickness Elements until you feel accustomed to these
features. It is important to note that all the information on the old mesh is
initialized. Click on the Ok button when you are finished.
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Checklist
1. Generated a system defined mesh on Object #1 with 200 elements
4.4. User-Defined Mesh Density.

Go back to mesh windows to generate User Defined Mesh Density, set the Mesh
Density from System to User in the MESHING/REMESHING window. The
DENSITY SPECIFICATION window will appear in the lower left corner of the
DISPLAY window. Click on the Boundary Density Specification button, set
the Density text box to 2 and press Enter. Click on all four sides of the disk to
apply a mesh density of 2 to these surfaces as shown in Figure 4.4. Now change
the density specification to Internal Density and the Density value to 1 and click
on the inner portion of the disk approximately six different places about the
inner region (Figure 4.4). This will give the surface of the object a mesh roughly
twice as dense as the surface of the ring. Change Number of Mesh Elements to
600. Click on the Generate Mesh button in the MESHING/REMESHING
window when you have finished. The mesh will appear in the DISPLAY
window when it is generated. Click on the Ok button once the mesh is
generated.
Figure 4.2: Example of User Definition of Mesh Density.
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Checklist
1. Generated user defined mesh as shown in Figure 4.4

Click on the Ok button in the Objects window. Anytime you change any object
data you should save your changes to a keyword file. Click on the Save
Keyword File disk icon located next to Keyword in the Control window.
4.6. Exiting DEFORM

When you have saved the keyword file, you can exit DEFORM-2D by clicking
on the Exit button at the bottom of the CONTROL window. You will be asked,
Are you sure that you want to exit the Pre-Processor?" click on the Yes button.
If you want to continue to the next lab go to the next page, otherwise click on the
Exit button in the DEFORM-2D SYSTEM window.
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5. MODELING OF HEATING PROCESS OF WORKPIECE

WITHOUT TRANSFORMATION 1
5.1. Opening a Previously Saved Problem 1
5.2. Setting Up Simulation Controls 1
5.3. Inputting Material Properties of the Workpiece 2
5.4. Defining Deformation Boundary Conditions 4
5.5. Defining Temperature Boundary Conditions 5
5.6. Initializing the Temperature of the Workpiece 6
5.7. Generating a Database File 6
5.8. Running the Simulation 6

Step Selection 7
Simulation Summary 8
Contour Plots 8
Vector Plots 8
5.10. Exiting DEFORMTM 8

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5. Modeling of Heating Process of

Workpiece without Transformation
5.1 Opening a Previously Saved Problem

Make sure that you are in the MAIN DEFORM window. Change to the
directory called RING. Double click on the filename RING.KEY and enter the
Pre-Processor to define your simulation data by clicking on the Pre-Processor
button. The DEFORM Pre-Processor will appear. You will be prompted
whether or not you would like to load the existing keyword file RING.KEY.
Click on the Yes button to load the file.
5.2 Setting Up Simulation Controls
Click on the Simulation Controls button in the CONTROL window. The

SIMULATION CONTROLS window will appear. Follow the instructions given
below to setup the simulation controls for this simulation (Figure 5.1).
1. Locate the Simulation Title text box and title the simulation as Ring.
2. Change the Operation Name to Heating.
3. Set the Units to SI.
4. Note that the Object Geometry is set to Axisymmetric.
5. Set the Heat Transfer to Yes.
Click on the Stopping Step button when you are finished with the above tasks.
In the STOPPING STEP window,
1. Set the Number of Simulation Steps, NSTEP to 50.

2. Set the Step Increment to Save to 5.
3. Set the Primary Die, PDIE(1) to 1.
4. Select the stepping criteria to be a function of Time and set the Time per
step, DTMAX, to 10 seconds.
Click Ok in the STOPPING and STEP CONTROLS window and then click Ok
in the SIMULATION CONTROLS window.
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Figure 5.1:Simulation Controls Window.
5.3 Inputting Material Properties of the Workpiece
To load the elastic and thermal data for this simulation, go to the menu bar at the
top of the control panel and select the File option. Under the Keyword option,
Load a file named STEEL_S.KEY. This file contains the elastic and thermal
properties of generic steel in SI units. In the CONTROLS window, click on the
Material Properties Icon (Figure 5.2). The elastic properties that were loaded
in the Pre-Processor are shown, Youngs Modulus, Poissons Ratio and Thermal
expansion. Note that the coefficient of thermal expansion is
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zero, thus there will not be a volume change upon heating. In order to make this
a coupled problem (i.e. deformation and thermal analysis), change the thermal
expansion from zero to 1e-05.
The thermal properties are able to be viewed by pressing on the tab named
Thermal. The Emissivity is given as a constant, however, the thermal
conductivity and heat capacity are functions of temperature. In order to see the
plot of thermal conductivity versus temperature, press the yellow highlighted
Table Entry Icon directly to the right of the thermal conductivity keyword. This
will show the tabular data and a plot of the thermal conductivity versus
temperature. Press OK when you are finished looking at the data.
The plastic flow stress data can be modified or entered to the Pre-Processor by
pressing the tab titled Plastic. Select the Flow Stress keyword to be a function
of effective strain, effective strain rate and temperature, which is the second
Figure 5.2: Material Properties Window.
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equation listed . Next click on the Flow Stress

Database Icon that appears as a file cabinet. This will call the MATERIAL
DATABASE window. Highlight AISI-1035 and click OK. This will load the
flow stress data for AISI-1035 steel into the Pre-Processor. In order to examine
the data, press on the Flow Stress Data Icon in the MATIERAL PROPERITIES
window. This will bring up the MATRIX DATA window. The graph of flow
stress versus strain for various strain rates are seen in the graphics window.
Press OK when you are finished with the MATRIX DATA window. Press OK
again to go back to the CONTROLS window.
Checklist
1. Loaded STEEL_S.KEY
2. Changed thermal expansion of object 1 (RING) to 1E-05
3. Defined the flow stress as a function of effective stress, effective strain rate,
and temperature
4. Loaded flow stress data AISI-1035
5.4 Defining Deformation Boundary Conditions
Figure 5.3: Example of Deformation Boundary Conditions.
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Press on the Objects button in the CONTROLS window to bring up the

OBJECTS window. Press the Boundary Conditions button. Under BCC Type,
velocity is the default parameter. For this example, the ring will be fixed in the
vertical direction. The part is axisymmetric and thus does not need to be fixed in
the horizontal direction. Set the direction of the velocity to the Y Direction by
clicking Y. Now click on the lower, left node, twice, once for the start and once
for the end. This will make this node the starting and ending point for the zero
velocity. After this, click on the Generate BCCs button to fix the node in the y
direction.
Checklist
1. Defined velocity in Y direction to be zero at the corner node of object 1.
5.5 Defining Temperature Boundary Conditions
In order to select the thermal boundary conditions, press on the tab titled
Thermal. The default selection parameter for the thermal boundary conditions is
Heat Exchange with Environment. This function allows the user to set which
nodes on the surface of the object are exchanging heat with the surrounding
environment. In the case of this lab, the entire piece is exchanging heat with the
environment. Upon setting boundary conditions on an object it is important to
keep in mind that the program orients the starting and stopping points in a
counterclockwise fashion about the object. Click on any point on the boundary
of the object. You should observe the node highlighted and the word Start
should appear near that node. Now click on the node to the immediate clockwise
node of the selected node. The word End should appear next to this node. Now
click on the Generate BCCs Icon. This will generate the Heat Exchange with
Environment boundary conditions for this object.
At this point we have specified heat exchange with the environment, now we
need to specify values for convection and radiation. Click OK in the
BOUNDARY CONDITIONS window and then click OK in the OBJECTS
window. Click on the Simulation Controls Icon and then click on the Processing
Conditions button. Set the Environment Temperature to 1000 C and set the
Convection Coefficient to 0.1 N/(sec*mm*C). Now the thermal boundary
conditions are specified. Click OK in PROCESSING CONDITIONS and then
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click OK in the SIMULATION CONTROLS window to go to the main

preprocessing window.
Checklist
1. Set BCC heat exchange with the environment for the entire object.
2. Set Environment temperature to 1000 C and Convention Coefficient to 0.1
N/(sec*mm*C)
5.6 Initializing the Temperature of the Workpiece

The last variable to specify for this lab is the initial temperature of the
workpiece. In order to do this click on the Objects button and then click on the
Temperature button. Set the temperature to 20C and click on the Ok button.
Click Ok in the Objects window to return to the Control window.
Checklist
1. Set object temperature to 20 C
5.7 Generating a Database File
In order to generate a database file click on the Database Icon in the

CONTROLS window. This will open the DATABASE GENERATION window.
Click on the Check Icon that will check the current pre-processor information to
see if a database can be generated. If there are no errors shown, then the
database can be generated. Click on the Generate Icon to generate the database.
Click Ok and the click on the Save Keyword File icon in the Control window to
save the keyword file. Exit the Pre-Processor by clicking on the Exit button.
When you are asked whether you are sure you want to exit click on Yes.
5.8 Running the Simulation
In order run the simulation, go to the DEFORMTM SYSTEM window. Click on

the Simulation button, and then click Start Simulation to begin the simulation.
Click on the Ok button. Click on the Process Monitor to monitor the simulation.
When all of the steps are complete, click the Ok button.
Click on the Post-Processor button to post-process the results of the simulation.

You should see the message:
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Click on the Yes button to load the database file RING.DB.
The DEFORM Post-Processor should appear consisting of the DISPLAY

window and the CONTROL window.
Step Selection
In order to select the step to be viewed, there is a step list on the right side of the
DISPLAY window. You can click on the step to select it, or you can you can
use the following buttons:
First Step
Previous Step
Play Backwards
Stop Playing
Play Forward
Next Step
Last Step
The First Step button will select the first step in the simulation, while the Last
Step button will select the last stored step. The Previous Step button will move
back one step in the simulation. The Next Step button will move forward one
step in the simulation. The Play button will display each step, pause for a
moment, and load the next step in the simulation. When it reaches the end of the
simulation, it will cycle back to the beginning and continue playing. The Play
Backwards button behaves the same as the Play button, but will display the steps
backwards, or in the opposite order. To stop either Play Forward or Play
Backward, you must click on the stop button. Click on the Temperature Hotkey
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button which looks like a thermometer . You can now view how the
temperature changes in the simulation. Experiment with these controls until you
feel comfortable with them.
Simulation Summary
You can see overall results of any step by clicking on the Summary button in the
CONTROL window. The SIMULATION SUMMARY window will appear.
This contains information on the current database. You can view information on
the given variables for any object in any step of the simulation. First select a
step from the Step list, and then the object from the Object list box. The text
boxes for each variable will show the current values for the step and object
selected. Click on the Variables tab to view the variables of interest such as
nodal temperature. Click on the Eye icon (plot min/max) to view how the
minimum and maximum temperatures changed with time in the simulation. Click
on the OK button until you return to the main post-processing window.
Contour Plots
In order to view a contour plot of the objects, just select the variable you wish to
view from the Hotkeys at the bottom of the CONTROL window. Click on the
Effective Strain button. The DISPLAY window should change and display a
line contour plot of effective strain. You can change the plot type from Line
Contour to Shaded Contour by clicking on the Shaded Contour icon. The plot
should change to a shaded contour plot. You can change the step shown by
selecting a new step from the step list.
Vector Plots
In order to view a velocity vector plot, just click on the Vector button in the
CONTROL window. The DISPLAY window should change to display velocity
vectors of all nodes in the mesh. You can also display more than one plot at the
same time. Click on the Viewport Options button next to the selection button
and select a dual horizontal viewport. The screen should split and display two
copies of the original viewport. Now click in the bottom viewport. The outline
should change from gray to green, signifying it as the active viewport. Any
changes you make will now apply to this viewport.
5.10. Exiting DEFORMTM

When you are finished, you can exit the Post-Processor by clicking on the Exit
button at the bottom of the CONTROL window.
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6. MODELING OF COOLING PROCESS WITHOUT

TRANSFORMATION 1
6.2. Editing the Simulation Controls 1
6.3. Adding Heat Exchange Windows 2
6.4. Appending to an Existing Database 5
6.5. Running a Simulation 5
6.6. Post-Processing 6

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6. Modeling of Cooling Process

without Transformation
6.1. Opening a Previously Saved Problem

Make sure that you are in the MAIN DEFORM window. Change to the
directory called RING. Click on the filename RING.KEY and enter the Pre-
Processor to define your simulation data by clicking on the Pre-Processor button.
The DEFORM Pre-Processor will appear. To continue an old problem you
have to start from the last saved step in the old database. You will be prompted
to select a database step, click on YES. Select the last step (step 50) and click on
the OK button.
Checklist
1. Changed to directory RING
2. Loaded Step 50 of RING.DB database
6.2. Editing the Simulation Controls
Locate and click on the Simulation Controls button in the CONTROL window.
The SIMULATION CONTROLS window will appear. Locate the Operation
Name text box and title the simulation as Cooling. Click on the Stopping Step
button when you are finished. Set the number of simulation steps, NSTEP, to 20
and set the step increment to save, STPINC, to 4. Click OK in the STOPPING
and STEP CONTROLS window and then click OK in the SIMULATION
CONTROLS window.
Checklist
1. Named Operation Name Cooling
2. Set number of simulation steps to 20
3. Set the step increment to save to 4
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6.3. Adding Heat Exchange Windows
In this lab we will consider the case where the object is not subject to
uniform heat exchange boundary conditions.
Important Note:
It is very often the case in practice where some surfaces of an object
are subject to radically different thermal boundary conditions than
others. One example is the case of forced convection in which one
surface is incident of a high velocity fluid while the other sides do not
see a high velocity. The use of heat exchange windows can provide
localized definitions of heat exchange boundary conditions and allow
DEFORMTM to model this specific case.
The method by which this can be modeled is to use Heat Exchange

windows. From the CONTROL window, click on the Objects button.
Click on the Boundary Conditions button and select the tab marked
Thermal. A button marked Heat Exchange Windows should be present
at the lower right corner of the BOUNDARY CONDITIONS window.
Click on the Heat Exchange Windows Icon to bring up the HEAT
EXCHANGE window screen. The user can create up to ten windows
over the workpiece and each may specify a different environment
temperature, convection coefficient and emissivity. These values may
vary with respect to time and convection coefficient and emissivity may
also vary with respect to temperature. The windows can be of an
arbitrary shape but need to cover the boundary for which they are
relevant.
User Caution:
For any boundary that is not covered by a heat exchange window, the global
values are used such as the emissivity specified in the material properties
and the convection coefficient specified in the processing conditions.
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Figure 6.1: Demonstration of Heat Exchange Window Placement.
For this lab, we will define four different windows, one for each surface.
6.3.1. Bore Side (Inner Side) of Workpiece
In the HEAT EXCHANGE window, select Window 1 as the current

window to work on. Select the Add Point feature in the Point
Editing menu in the lower left corner of the
DISPLAY window. Upon defining a heat exchange window, it is
critical to note that the windows must be defined in a counterclockwise
manner. However, when the database is being generated Add four
points that enclose the bore side of the ring as shown in Figure 6.1. The
boundary enclosed by this window will be defined by what we specify in
the window information for window 1. In this lab we wish to specify
cool down by both radiation and convection. In the Heat Exchange
Windows window, specify the environment temperature as 20 C, the
convection coefficient as 0.02 N/(mm*s*C) and the emissivity as 0.6.
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6.3.2. Bottom Side of Workpiece
We will define the boundary on the bottom of the workpiece by first

selecting Window 2 in the HEAT EXCHANGE window. Notice that the
current window in the Display becomes grayed out. Thus the user can
see the previous window but is aware that it is not the current window.
Add a window that looks like Window 2 as seen in Figure 6.1. Note that
it is recommended to overlap the windows slightly. The reason is that
any boundary not covered by the heat exchange windows will take on
global values. Thus, to avoid small areas from having questionable
definition, it is better to have small overlap. After the window has been
constructed, define the environment temperature to be 20 C, the
convection coefficient as 0.09 N/(mm*s*C) and the emissivity as 0.8.
6.3.3. Outer Side of Workpiece
Use the third window to define the outer side of the workpiece. Make
sure that his window overlaps the adjacent window slightly and define
the environment temperature to be 20 C, the convection coefficient to be
0.02 N/(mm*s*C) and the emissivity to be 0.9.
6.3.4. Top Side of Workpiece
Use the fourth window to define the boundary for the top of the
workpiece. Define the environment temperature to be 20 C, the
convection coefficient to be 0.01 N/(mm*s*C) and the emissivity to be
0.8. After this is completed, press OK in the HEAT EXCHANGE
window and then in the BOUNDARY CONDITIONS window and then
in the OBJECTS window.
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Checklist
1. Set Window 1: Environment temp: 20 C Convection Coef: 0.02
Emissivity:0.6
Emissivity:0.8
Emissivity:0.9
Emissivity:0.8
6.4. Appending to an Existing Database
Now that the data has been changed, the current step -51 must be added to the
current database. Click on the Database... button in the CONTROL window.
The DATABASE GENERATION window will appear. Make sure that the
Database Type is set to Old. If the type is New, then the old database will
be deleted when you generate step -51. Click on the Generate button to add the
current step, and click on the Yes button in the ADDING TO OLD DATABASE
window. Click on the OK button in the DATABASE GENERATION window
when you are finished. Exit the PRE-PROCESSOR and prepare to continue the
simulation.
6.5. Running a Simulation
From the SYSTEM window, click on the Simulation button. Once the
simulation has been started, monitor the simulation from the PROCESS
MONITOR window.
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6.6. Post-Processing
Figure 6.2: Initial Post-Processing Window
Click on the Post-Processor button to Post-Process the results of the simulation. You
should see the message like Figure 6.2. Click on the Yes button to load the database file.
Step Specification
For the exception of the very first step, the DEFORMTM Post-Processor will only show
the positive steps when loading a database. To show the negative steps in the Post-
Processor, click on the Steps icon. All available steps will be shown in the STEP
SELECTOR window. To make all the steps available, click on the All Steps button.
This will highlight all the steps in white. After this is done, click on the OK button. The
negative step will be shown now in the main Post-Processing window.
Point Tracking
To track certain points on the boundary of an object, click on the Point Tracking button
in the CONTROL window. The POINT TRACKING window will appear (Figure 6.3).
First you must define the points to track, so click on the Define Material Points and
Track button.
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Figure 6.3: Point Tracking Window
The DISPLAY window should change and show an outline of object 1 and the
DEFINE/TRACK POINTS window will appear. To add a point to track, click
on the object where you would like to track a point. As you add points, their
coordinates will appear in the Defined Points Table in the DEFINE/TRACK
POINTS window (Figure 6.4).
Figure 6.4: Object with selected tracking Points and

Material Points window.
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Set the first point in the upper right hand corner of the object. Now place a
second point in the center of the object. Place a third point in the lower left
corner of the object. If you make a mistake, you can delete a point by clicking
on the Delete Points button in the lower left corner of the Display window.
To add points again, just click on the Add Points button. Once all points have
been defined, click on the OK button in the DEFINE/TRACK POINTS window.
All points in the simulation will then be tracked (Figure 6.5).
Figure 6.5: Tracking Progress Window
To view point tracking graphs, you must create a secondary viewport. Select a dual
horizontal viewport from the Viewport Options button in the DISPLAY window.
Now click on the lower viewport to select it as the current viewport. To plot point
tracking data in this viewport, click on the Generate Point Tracking Graphs
button in the POINT TRACKING window. The POINT TRACKING GRAPHS
window will appear from which you can select the graph options as shown in Figure
6.6.
Figure 6.6: Point Tracking Graphs

Window.
Set the Variable to Temperature and click on the OK button. The Time vs.
Temperature data for your simulation should now appear in the lower viewport
(Figure 6.7). Click on the OK button in the POINT TRACKING window.
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Figure 6.7: Object with selected points and Temperature-Time plot.
Now when you play through the steps, a vertical line will appear on the Time vs.
Temperature graph to indicate where the current step is on the graph. You can
zoom in on any area of the graph using the Dynamic Zoom and Zoom Window
buttons. You can also measure the difference in both time and temperature between
any two points on the graph user the Ruler button in the DISPLAY window. Once
you have finished viewing the data, exit the Post-Processor.

To exit the DEFORM System, click on the Exit button in the DEFORM SYSTEM
window.
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7. ENTERING MATERIAL AND INTER-MATERIAL DATA

FOR A TRANSFORMATION SIMULATION 2
7.1. Creating a New Problem 4
7.2. Setting Simulation Controls 4
7.3. Setting Material Properties 4
7.4. Setting Inter-Material Properties 9
7.5. Saving a Keyword File 13
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Lab Objective:
The purpose of this lab is to acquaint the user with inputting properties required to
model a phase transformation in DEFORMTM. In this lab, the user will see how to define
in DEFORM the data necessary to model phase transformations for plain carbon steel.
A basic description of how transformation affects both deformation and heat transfer is
shown in Figure 7.1. As shown in the center of the relation in Figure 7.1, the operation of
all three nodes is a function of the carbon content of the steel. Since the concentration of
carbon may vary throughout the steel, the mechanical and thermal properties of the steel
will be non-homogenous.
Figure 7.1 shows a few example relationships and it is not intended to be exhaustive,
however, it does show that transformation is highly coupled to both deformation, heat
transfer and carbon content. In Figure 7.2, the relationships of four different phases of
plain carbon steel are shown. Austenite exists at higher temperatures while Martensite
and Bainite are metastable phases at lower temperatures. The metastable phases can be
produced by rapidly cooling Austenite. Each phase is defined by its own set of material
properties. These material properties define the plastic behavior of the phase, the thermal
properties of the phase, and possibly (if using an elasto-plastic material) the elastic
properties of the phase. The relationship between the transformation from one phase to
another is defined by the Inter-Material properties. This relationship is defined in terms
of a kinetics model (in order to determine rate of phase transformation) and a few
relational properties such as latent heat and volume change. The principle interest of the
user is how to make use of the data that exists in available tables and charts for a heat
treatment simulation. This is the ultimate goal of this lab. The key concepts for the user
to look for are:
1) What material properties are required to define a phase for the current simulation?
2) What data is required to describe the change between the phases?
3) How can one make use of existing tables and graphs for a DEFORMTM heat treatment
simulation?
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H e a t G e n e ra te d b y D e f o rm a tio n
D e fo rm a tio n H eat T ran sfer

T h e r m a l E x p a n s io n
C a r b o n C o n te n t
L a te n t
H eat
T e m p e r a tu r e in d u c e d
S t re s s in d u c e d T r a n s f o r m a tio n
T ra n s f o rm a tio n
T r a n s f o r m a tio n
P la s tic i ty
T r a n s f o r m a tio n
Figure 7.1: Diagram on Inter-relation between three modes in Metal forming
M artensite
(M aterial
Properties)
Inter-M aterial
Properties
A ustenite
(M aterial
Properties)
Inter-M aterial
Properties
E xam ple M aterial P roperties B ainite

Y oungs M odulus (M aterial
T herm al C onductivity Properties)
E xam ple Inter-M aterial Properties

L atent H eat
V olum e C hange
Figure 7.2: Diagram on Inter-relation between different phases of steel
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7. Entering Material and Inter-Material Data for a

Transformation Simulation

Create a directory called STEEL, change to that directory. Set the Problem ID to
STEEL and click on the Pre-Processor button to enter the Pre-Processor to define
your simulation data.. The DEFORM Pre-Processor will appear consisting of
the DISPLAY window, the CONTROL window, and the MESSAGE window.
Checklist
1. Running DEFORMTM-2D in directory STEEL
Locate and click on the Simulation Controls button in the CONTROL window.
The SIMULATION CONTROLS window will appear. Set the UNITS to SI.
Locate the Simulation Title text box and title the simulation as STEEL_DATA
and then click OK in the SIMULATION CONTROL window.
Checklist
1. Titled Simulation Title as STEEL_DATA
2. Set units to SI
7.3. Setting Material Properties
The purpose is to set-up all the material properties for three phases of steel and
to define them as a mixture. The three phases are Martensite, Bainite and
Austenite. These components combine to define the mixture, in this case, AISI-
1045 steel. In the material properties section we will define the elastic, plastic
and thermal data for each phase. These phases will define the mechanical
properties for the AISI-1045 steel using a weighted volume fraction of the
component phases. In this section of the lab, the user will input the required
material properties for Austenite (for use in an elasto-plastic material simulation)
and then load the rest of the material data from a file. It is important for the user
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to note that the purpose of this section is to become familiar with the
DEFORM interface.
Question: What is the difference between a phase

and a mixture?
A phase is a region of material that has uniform physical and

chemical properties. A mixture is defined as a set of phases (at
least 1 or more phases). The phase properties are used for the
mixture except for the Jominy and Cooling curve data. If data is
specified for the mixture aside from the Jominy and Cooling
Curve data then the FEM engine will not use the data.
7.3.1. Elastic Data
Click on the Material Properties button in the CONTROL window. There will
be a default material group in the material properties section.
1) Change the name of the current material from MATERIAL 1 to Austenite.

2) The default setting for Material Type should be Phase.
3) Click on the Elastic Tab in the MATERIAL PROPERITIES window.
This will allow us to edit the values for Youngs Modulus, Poissons Ratio and
the coefficient of Thermal Expansion. The value of Young's Modulus will be a
function of atom content and temperature so click on the Constant/Function Icon
for Youngs Modulus to activate the Table Entry icon. Click on the Table Entry
Icon to open the TABLE ENTRY window. By default, the x-axis Data will be a
Constant, change this to Temperature and Atom. This will allow the Youngs
Modulus value to vary with respect to temperature and dominant atom content.
(In the case of steel the dominant atom content is carbon).
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Question: What is meant by dominant atom content?

In DEFORM Heat Treatment Module the atom content is considered in the
simulation. For example, in the case of steel, the variation of carbon throughout the
object will influence the amount of austenite transformed to martensite. The
dominate atom content is defined in terms of weight percent. For example, if the an
atom content of 0.14 means 0.14 wt% atom content. In addition, the atom content
affects the physical properties of the material. The atom percentage can be any
impurity to the material so long as it requires the modeling of chemical reactions in
the material.
The TABLE ENTRY window (Figure 7.3) is arranged so that the top two data
entry boxes specify the values of Atom Content and Temperature for which the
Youngs Modulus is defined. The data entry box located just below the center of
the TABLE ENTRY window defines the values for the Youngs Modulus for the
specified values of Atom Content and Temperature.
Figure 7.3: Table Entry Window
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1) Click in the upper left-most data entry box with Atom directly above it and
then click on the Insert Row icon. This will add another row to the Atom
Content variable.
2) Make the value for the first entry 0.14 and the second entry 0.6.
3) Now click on the data entry window directly to the right of the previously
edited window.
4) Click on the Insert Row icon five times to insert five extra values for
Temperature.
5) Type in the values of temperature 0, 200, 400, 600, 800 and 900, in
increasing order.
6) To enter the values for Youngs Modulus in the matrix, go to the matrix in
the lower portion of the TABLE ENTRY window and enter in the following
values:
Temp Atom
0.14 % 0.6 %
0C 204468 198580
200 C 192900 187361
400 C 175416 170415
600 C 152018 147742
800 C 122704 119342
900 C 114451 111347
7) Press the Apply button when you are finished with typing the above data in
the TABLE ENTRY window. You should see two curves in the DISPLAY
window.
8) Press the OK button.
Note that for a complete set of Elastic properties, the Poissons ratio and thermal
expansion coefficient would have to be defined. The same procedure would be
followed, however we will be loading the remaining elastic properties from a
keyword file later in the lab.
7.3.2. Plastic Data

Click on the Selector Tab titled Plastic. This will allow the plasticity properties
for the current material to be edited. The current function for the flow stress
should be by default a function defined by four constants c, n, m and y. Change
the flow stress definition type to the table type:
_ _ .
= ( , , T )
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Click on the Flow Stress Data icon to obtain the MATRIX DATA window.
Change the Temperature value to 20 C and add a row to both the Strain Rate and
Strain data entry windows. Input the value of Strain Rate to be 1.5 and 1.6 and
input the value of Strain to be 0.1 and 0.7. For the Flow Stress values, place the
following values in the matrix just below the center of the window.
Strain Strain Rate
1.5 1.6
0.1 688.963
688.963
0.7 904.711
904.711
Click on OK when all the flow stress values have been input to the system.
Question: What is flow stress?
The definition of flow stress is the stress required to perform incremental plastic
deformation on a material. For example, if a material is being deformed plastically, the
effective stress in the material is determined from the flow stress data based on the
temperature, strain and strain rate at which the material is being deformed. Once the
plastic deformation is discontinued, the flow stress is the stress required to resume
plastic deformation.
7.3.3. Thermal Data
1) Click on the tab marked Thermal in the MATERIAL PROPERITES window

to edit the thermal properties of the current material.
2) Click on the Constant/Function button for Thermal Conductivity and then
click on the Table Entry button.
3) Click on the Temperature and Atom option for the X Axis Data.
4) Just as in the previous examples, set the values for atom to 0.14 and 0.6.
5) Set the values for Temperature to be 0, 200, 400, 600, 800 and 900 C.
6) For the thermal conductivity values, place the following in the matrix just
below the center of the TABLE ENTRY window.
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Temperature Atom Content

0.14 0.6
0 22.32 21.48
200 24.01 23.04
400 25.7 24.59
600 27.39 26.15
800 29.08 27.71
900 29.93 28.49
7) Press OK when all the thermal conductivity data is entered.

8) Exit the Material Properties window. Load the Keyword file AUSTEN.KEY
from the CONTROL window to load the rest of the material properties for
the other phases of steel. Now, go back into the Material Properties window.
By clicking on the Material Properties icon, one can note that the fourth
material group is not a phase but rather a mixture of the first three material
groups. Thus, the material properties of the fourth group is determined by a
volumetric-weighting of the first three material groups. Click OK when you are
finished.
7.4. Setting Inter-Material Properties
Click on the File option on the menu bar in the CONTROLS window and load
the Keyword file TRANS.KEY. This file is a TTT relation to be examined by
the user. In this section, due to the complexity of existing TTT diagrams the
user will just load the data and then look at the data carefully to gain an
appreciation on how to input data from an isothermal TTT diagram into the Inter
Material Properties section. Click on the Inter Material button in the CONTROL
window to bring up the INTER MATERIAL PROPERITES window. The
purpose of this window is to assign relationships between material
transformations from one material to another material. All the materials that are
defined in the Material Properties section are all seen at the top of the INTER
MATERIAL PROPERITES window. The purpose of this section of the lab is to
define the relationship of the transformation from Austenite to Bainite. This
transformation occurs during cooling, usually at a rather high rate.
1) Highlight the Austenite material in the Material 1 table by clicking on the
Austenite entry.
2) Highlight the Bainite material in the Material 2 table by clicking on the
Bainite entry.
3) In the Parameters section of the INTER MATERIAL PROPERITES window
note that the Phase1 Phase2 option has been defined already. This
defines that the austenite phase may transform into the bainite phase
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assuming that the process conditions satisfy the kinetics model specified for
the transformation.
4) The next specification required is which kinetics model to use to model the
transformation of Austenite to Bainite. The kinetics model used for this
transformation will be a diffusion model.
Click on the tab Kinetics and note the Kinetics model titled Diffusion f(Temp,
Stress, Atom). This model requires the user to input data in the form of an
Isothermal TTT diagram. Note that there are three values that can be specified
in the Kinetics selection window. These values are the Avrami exponent n, the
beginning transformation (Curve 1) curve and the ending transformation curve
(Curve 2). In order to understand the model, lets look at a graphical
representation of the model. Click on the Data icon.
The model specified requires data input in the form of a TTT diagram, either
defined with one curve and the Arvami equation or two curves. In the case of
two curves, the first curve is a plot of temperature versus time for a specified
value of initial phase volume fraction (specified by the Curve 1 VF variable).
This volume fraction could be set to 1 % or less, but it must be greater than zero.
The second curve is a plot of temperature versus time for a specified value of
final phase volume fraction (specified by the Curve 2 VF variable). This volume
fraction could be set to 99 % or greater. DEFORMTM can predict the amount of
transformation at a given effective stress and dominate atom percentage from the
inputted plots (See Figure 7.4 for an example curve).
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Figure 7.4 shows a simplified TTT diagram. It shows a TTT diagram for a
transformation from phase 1 to phase 2 at an effective stress of 300 MPa and a
carbon content of 0.44 wt %. The curve on the left side of the plot is the initial
volume fraction and the curve to the right is the volume fraction. The Display
Figure 7.4: Example TTT Diagram.
window will look like Figure 7.5. (It is important to note that the time is in log
base 10, not in seconds). There are six curves in diagram covering three carbon
concentrations and an initial and final phase transformation. In this case, the
start curve is 1 % transformation and the final curve is 99 % transformation.
These values are can be seen in the INTER-MATIERAL window. The number
of curves used in the model is specified in the upper left of the Matrix Data
window. If the number of curves in the Matrix Data window is set to two, then
the Avrami n number specified in the previous window is not necessary.
However, if only one curve is specified, then an Avrami n number is required
to give DEFORM sufficient information to solve for volume fraction.
After the user has sufficiently perused this feature, press OK to return to the
INTER MATERIAL PROPERITES window. Click on the Transformation Tab.
The Latent Heat is defined to be 595.36. Latent Heat is the amount of heat
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generated as a result of the transformation. Click on the Constant/Function

button next to the Volume change and then click on the Table Entry button to
view the results. After you done looking at the data click on the Ok button in the
Matrix Data window and click Ok in the Inter-Material window.
Figure 7.5: TTT diagram for austenite to bainite transformation.
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Question: How is DEFORMTM solving for volume fraction in the

Diffusion model f(Temp, Stress, Atom)?
DEFORMTM is trying to solve an Avrami equation, which has the form
= 1 exp(kt n )
where is the volume fraction transformed, t is the time and k and n are constants (n
being the Avrami number). In terms of TTT data, two curves are required in order to
solve for k and n. If only one curve is input to DEFORMTM, the user must provide
the Avrami number.
Question: OK, what data do I need to construct a TTT Diagram in

DEFORMTM?
The data required depends on the type of accuracy that is required for a problem. The
independent variables are the atom content in the material, the temperature during the
transformation and the stress that the material phase is under. Also, two curves are
recommended to represent the starting and stopping volume fractions. Typically, a TTT
diagram consists of one or two curves for a specific atom concentration and a specific
stress state.
7.5. Saving a Keyword File
From the CONTROL window, click on the Disk Icon next to the Keyword name
to save this session as a keyword file.

To exit the DEFORM System, click on the Exit button in the DEFORM
SYSTEM window.
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8. MODELING OF A HEATING OPERATION WITH

TRANSFORMATION. 1
8.1. Creating a New Problem 1
8.2. Loading the Material Properties 1
8.4. Creating New Objects 2
8.5. Defining Inter-Object Relations 7
8.6. Generating a Database 8
8.8. Post-Processing the Results 8

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8. Modeling of a Heating Operation

with Transformation.

Create a directory called Transform, change to that directory. Change the
Problem ID to Transform. Click on the Pre-Processor button and enter the Pre-
Processor to define your simulation data.
8.2. Loading the Material Properties
Go to the File option in the menu bar and load in the keyword file,
MAT_TTT.KEY. This will provide you with all the material properties for the
next three labs.
Click on the Simulation Control icon in the Controls window. Set the following
parameters:
1) Change the Operation Name to Heating.

2) Change the units to SI.
3) Change the object geometry to Plane Strain
4) Turn on Deformation, Transformation and Heat Transfer.
5) Click on the Stopping Steps controls button and change the number of steps
to 2000.
6) The step increment to save should be set to 10.
7) The PDIE(1) value should be set to 1.
8) Stepping should be performed by Time (DTMAX) and a rate of 2 seconds
per step.
9) Click on the Stopping Controls Tab.
10) TMAX should be set to 3600 seconds.
11) Click on the Step Controls Tab.
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12) Now click on the Advanced Step Controls to modify the stepping criteria
of the simulation. Change the temperature change per step to 5 C and the
Temperature change time step to a range of 2 s and 20 s.
13) The Step Definition should be changed to temperature based by selecting
the Temp option in the radio button.
14) Press Ok in the Advanced Step Controls window, press Ok in the Stopping
and Step Controls window.
15) Click on the Processing Conditions button in the Simulations Controls
window and set the Environment temperature to 850 C.
16) Set the value of the Convection Coefficient to 0.1 N/(s*mm*C).
17) Press Ok in the Processing Conditions window and press Ok in the
Simulation Controls window.
Question: What is temperature based stepping?
This is a method by which the time step size is determined by using the
calculated temperature gradient from the previous step to estimate a user defined
maximum temperature change. The parameters that need to be set are the
desired maximum temperature change, the largest allowable time step size and
the smallest allowable time step size. Also, the Step Definition needs to be
changed to Temp in order that the first step of the simulation DTMAX is
calculated while the rest of steps are determined from the temperature field.
Object #1:
At this point, the user will insert all the objects required for this
simulation.
1) Click on the Objects button in the Control window.
We need to load the workpiece geometry and create a mesh for it.
2) Change the Object name to Gear Tooth.
3) Click on the Geometry button in the Objects window and load the
IGES file TOOTH.IGS.
4) After the gear tooth has been loaded reverse the geometry to make it
counter-clockwise.
5) Click on the Check Geometry button to ensure that the geometry is
legal.
6) Click Ok in the Geometry window.
7) After this, click on the Mesh icon in the Objects window.
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Set the number of mesh elements to 500 and adjust the weighting factor for the
meshing such that boundary curvature has a weighting factor of 1 while leaving
the other weighting factors unchanged. Set the number of thickness elements 4
and the maximum size ratio between elements 3.
8) Generate the mesh for the gear tooth and press Ok.
9) Set the Material type Elasto-Plastic.
10) Click on the Boundary Conditions icon and set the vertical velocity
to zero for the bottom section. (Figure 8.1).
11) Click on the thermal tab in the Boundary Conditions window to set
the heat exchange boundary conditions (Figure 8.2).
12) Set the thermal boundary conditions to Heat Exchange with the
Environment for the outside part of the tooth and the bore (inner)
section.
13) Press Ok when finished when applying these boundary conditions.
14) Click on the Material icon to bring up the Material Selection
window. This is the window in which the material type is selected
for a particular object.
15) Click on the AISI-1045, COLD selection and press Ok.
Figure 8.1: Gear tooth section with velocity boundary conditions.
At this point the temperature and the phase composition of the object needs
to be defined.
Question: What are weighting factors and why are they necessary?
Weighting factors are variables that one can assign in order to emphasize or deemphasize
the density of the mesh based on object parameters. By increasing the weighting factor for
boundary curvature, the mesh generator will tend to place more elements in regions where
the boundary of the object has higher curvature.
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Figure 8.2: Gear tooth section with heat exchange boundary

conditions.
16) Click on the Default icon and set the Temperature to 20 C and the Atom
percent (weight percent) to 0.14.
At this time the user will initialize the phase composition of the object.
17) Click on the Objects Tabs, then click on the Elements Data Icon and click
on the Transformation Tab to see where the composition of the object
material is defined. (Figure 8.3)
Figure 8.3 Element window with Transformation data
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This window specifies several values in for the object phase composition. The
value, VOLFC, is the volume fraction of a specific phase in the object. The sum
of the volume fraction values for all the phases at any time must be equal to
unity. The user can initialize the object to be pure Bainite at the beginning of the
simulation by clicking on the VOLFC value for the Bainite phase and then
clicking on the Initialize Values icon directly to the left. Click on the Bainite
box to make it the active box and click on the Initialize button (I) next to the
table. Set the value to 1 and click on the Ok button. Initialize the VOLFS
variable for Bainite to be unity as well, following the same procedure. The
VOLFS variable specifies the transformation limit of a given phase. Thus, by
specifying a value for VOLFS of 1.0, 100 % of the Bainite is allowed to
transform into Austenite.
18) Press Ok in the Initialize Elements window and then press Ok in the
Elements window.
19) Click on the Properties icon in the Objects window and change the EP
Initial Guess to Use previous step solution.
20) Click Ok in the Object Properties window.
Question: What is meant by EP Initial Guess?

In order to solve an FEM problem, a numerical solver is required. DEFORM uses Newton-
Raphson or Quasi Newton-Raphson to solve for the deformation of elasto-plastic materials.
However, for both of these methods, an initial guess is required. As the initial guess gets better,
the speed and likeness of convergence increases. By default, the FEM engine uses a rigid-plastic
calculation as the initial guess for an elasto-plastic material. Another method that DEFORM
may implement is to perform the calculation for an elastic material. The third method is to use
the result from the previous step as the intial guess. This is usually the best method if the
deformation in the object is small.
Object #2:
This object will be used for the sole purpose of constraining object 1.
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Question: Exactly what situations would I use a rigid plane to constrain a

workpiece?
A rigid plane may always be used as a plane of symmetry. A zero velocity condition may be
easier to define but in a case where a plane of symmetry is required in a direction that does not
correspond to an axial direction (such as the X-axis or the Y-axis), the only method available is
to use a rigid plane. A rigid plane acts exactly like a plane of symmetry in that the nodes can
move into the plane. Other requirements on the plane are that the nodes are not allowed to
separate from the plane (defined by seperation criteria in InterObject Conditions), the plane is
the master of the workpiece (also InterObject Conditions), the friction between the two objects
is zero (InterObject Conditions) and that the rigid plane is sufficiently large to completely cover
the symmetry plane of the workpiece.
1) In the Objects window, add another object by clicking on the Add Object icon. This
object number will default to 2.
2) Select this object 2 and change the name of this object to Plane.
3) Click on the Geometry icon in the Objects window and click on the Load IGES file
icon.
4) Load the file Plane.IGS as object 2 and press Ok in the Geometry window. Your
screen should look like Figure 8.4.
The purpose of this object is to serve as a plane of symmetry where no material may
cross. The key to making this act as a true plane of symmetry is to set the interface heat
transfer to zero, the friction to zero and the placing a no seperation criteria between the
two objects. These parameters will be prescribed later.
5) Click Ok in the Objects window.
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8.5. Defining Inter-Object Relations

1) Click on the Inter Object icon in the Control window.
2) Click on the Interface Conditions icon to define the relationship of object #1
to object #2.
3) In the Object 1 table, select object 1 and select object 2 in the Object 2
table.
The Gear Tooth should be highlighted in red and the Plane should be highlighted
in green.
4) Change the contact relation between these two object from None to Slave-
Master.
5) Set the seperation criteria to Abs. Pressure and set the value to 1e+07. This
prevents the gear tooth from losing contact with the symmetry plane.
The friction and the heat transfer coefficient should both remain zero if the plane
is to act as a symmetry plane. The user may view the heat transfer relationships
Figure 8.4: Gear tooth with rigid plane.
by selecting the tab named Thermal.
6) Click Ok in the Inter Object Interface window.
7) Click on the Generate BCCs icon in the Inter Object window..
8) Click on the Generate BCCs icon in the Contact Boundary Conditions

window.
9) Click Ok in the Contact Boundary Conditions window and then press Ok in

the Inter Object window.
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8.6. Generating a Database

To generate a database file click on the Database Icon in the Controls window.
This will bring up the Database Generation window. Click on the Check Icon
that will check the current pre-processor information to see if a database can be
generated. If there are no errors shown, then the database can be generated.
Click on the Generate Icon to generate the database. Exit the Generate Database
window. In addition, it is a good to save the keyword file, so click on the Save
Keyword. Now, exit the pre-processor.

From the MAIN System window, click on the Simulation... button. Once the
simulation has been started, monitor the Simulation from the Process Monitor.
8.8. Post-Processing the Results

Click on the Post-Processor button to Post-Process the results of the simulation.
Load the database TRANSFORM.DB.
8.8.1 State Variables
The new state variable to investigate in this type of simulation is the Volume
Fraction variable. Click on the State Variable icon and select the variable
Volume Fraction under the Mic tab. You will see that you will be given the
option to select four components, which represent the possible phases and the
mixture component. Select the Bainite component and plot the variable as a
shaded contour. The user should see the variable initially having a value of 1.0
(which means 100 % of the structure is composed of Bainite) and eventually
falling to 0.0 (which means 0 % of the material is composed of Bainite). The
user should plot the other volume fractions to determine which component the
volume was converted to.
In addition, you should look at the volume change of the object as a function of
time. Click on the Simulation icon to open the Simulation Summary window.
Click on the eye icon next to the word Volume. A plot of the Volume as a
function of time should appear in the Display window. Click on the Ok button to
close the Simulation Summary window. Zoom in on the area of interest using the
zoom window function to observe how the transformation changed the volume
of the object. It should be noted that the transformation decreases the overall
volume of the object because austenite is the FCC structure while bainite
consists of lathe plates of ferrite (BCC structure) and cementite (orthorhombic
structure). FCC is a closed packed structure and hence smaller in volume than
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either BCC or any orthorhombic structure, therefore the volume of the object
will decrease when bainite transforms into austenite which can be observed in
the plot.
Austenite Transformation
107.0
Op 1 Op 2 Op 3
106.5
106.0
105.5
Volume
105.0
Op 4
104.5
104.0
103.5
0.E+00 3.E+03 6.E+03 9.E+03 1.E+04 2.E+04
Time (sec)
Figure 8.5: Complete heat treat process including heating. diffusion,

carbonizing, and quenching
Figure 8.5 shows a complete heat treat process. Notice that when the workpiece
transforms to Austenite the volume decreases because of the transformation
(BCC --> FCC). The curve changes slope (i.e. the volume begins to increase) as
a result of the continued heating of the workpiece.
How does DEFORM handle the volume change as

a result of transformation in a simulation?
The volume change is defined though the keyword
PHASVL. The Volume can be a function of temperature and/or
atom content. The data is inputted in tabular form in the Pre-
Processor or read from a keyword file.
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System window.
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9. MODELING OF CARBURIZATION OF A GEAR TOOTH

9.3. Setting Boundary Conditions 2

DEFORM-HT Labs
9. Modeling of Carburization of a Gear

Tooth
Create a directory called Carburize, move to that directory, type DEFORM2 and press ENTER.
The DEFORM System Window will appear. Enter the Pre-Processor to define your
simulation data. Click on the Pre-Processor button. The DEFORM Pre-Processor will
appear consisting of the Display window, the Control window, and the Message window. To
continue an old problem you have to start from the last saved step in the old database. Change
the Problem ID to Carburization. Go to the top menu bar and click on File. Select Load
Database and load the database TRANSFORM.DB. The Select Database Step window will
appear with a list of available steps to import. Select the last step and click on the Ok button.
1) Click on the Simulation Controls icon in the Controls window.

2) Change the Operation Name to Carburization.
3) Click on Yes for the Diffusion option and click on No for the Deformation
option.
4) Click on the Stopping Step controls button.
5) Change the number of steps to 500. Note that the total number of steps that
was left from the Transform database was equal to the number of steps set in
the previous lab less the steps made during the simulation.
7) The time per step should be set to 10 s.
8) Click on the STOPPING CONTROLS tab and set TMAX to 6000 seconds
and click on the Controls tab. Note that since the previous simulation has
been run to T=3600 s, effectively this step is only 2400 seconds long.
9) Click on the Advanced Step Controls and set temp change per step and
min/max time step to zero. Click Ok in the Advanced Step Controls window.
10) Press Ok in the Stopping and Step Controls window.
11) Click on the Processing Conditions button in the Simulations Controls.
12) Set the value of the reaction rate coefficient to 0.0001 mm/s and the
environmental atom content should be changed to 1.69 % atom.
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9.3. Setting Boundary Conditions
1) Click the Objects icons and click the Boundary Conditions icon in the Objects window.
At this point the user needs to define the boundary over which the carbon
bearing atmosphere is exposed to the workpiece. In this, the entire surface, both
the outer surface and the bore surface, will be exposed to a carbon-bearing
environment.
2) Click on the tab titled Diffusion and click on the icon titled Diffusion with the Environment.
3) Select and generate boundary conditions for both the bore of the gear and the outer surface of
the gear (Figure 9.1).
4) Press Ok in the Boundary Conditions window and in the Objects window.
Question: What do I need to set up a carburization simulation?
The user needs to define the following parameters in order to run a carburization
problem.
1) Set Diffusion to Yes.
2) Initialize carbon concentration in the material.
3) Set the reaction rate of the material.
4) Set the environmental atom content of the atmosphere.
5) Set the Diffusion Boundary Conditions for exchange with the environment.
Figure 9.1: Gear Tooth with Diffusion Boundary Conditions.
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9.4. Saving the Keyword
Click on the Ok button in the Objects window. Click on the Save Keyword icon.

Click on the Generate Icon to generate the database.

From the System window, click on the Simulation... button. Once the simulation
has been started, monitor the Simulation from the Process Monitor.

Load the database Carburization.DB.
9.7.1 State Variables
The new state variable to investigate in this type of simulation is the Dominant
Atom variable. Click on the State Variable icon and select the variable
Dominant Atom under the Dif tab and plot the variable as a shaded contour. The
user should see the variable having an initial uniform value of 0.14. The value
increases at the free boundaries to indicate the carbon absorbed and diffused into
the gear tooth.

System window.
Question: Can DEFORMTM-HT model Nitridization as well?
Currently, due to the nature of diffusion of Nitrogen through steel, DEFORMTM

cannot model this process. As nitrogen passes through steel, there are chemical
reactions that occur which make the modeling much more complex. 3
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10. MODELING OF DIFFUSION OF A GEAR TOOTH 1

10.6. Exiting DEFORMTM-HT 2

DEFORM-HT Labs
10. Modeling of Diffusion of a Gear Tooth
Create a directory called Diffusion, change to that directory, type DEFORM2 and press ENTER.
The DEFORM-HT System Window will appear. Enter the Pre-Processor to define your
simulation data. Click on the Pre-Processor button. The DEFORM-2D Pre-Processor will
appear consisting of the Display window, the Control window, and the Message window. To
continue an old problem you have to start from the last saved step in the old database. Change
the Problem ID to Diffusion. Go to the top menu bar and click on File. Select Load Database
and load the database Carburization.DB. The Select Database Step window will appear with a
list of available steps to import. Select the last step and click on the Ok button.

2) Change the Operation Name to Diffusion.
4) Change the number of steps to 150.
6) Click on the STOPPING CONTROLS tab, TMAX should be set to 13200 seconds and click
on the Controls Tab.
7) The time per step should be set to 60 s.
8) Click on the Advanced Step Controls icon.
9) Change the maximum temperature in the Temp change time step to 60 s and click Ok.
10) Press Ok in the Stopping and Step Controls window.
12) Set the value of the reaction rate coefficient to 0 mm/s and the environmental atom content
should be changed to 0 % atom.
13) Press Ok in the Processing Conditions window and press Ok in the Simulation Controls
window.
14) Save the keyword file by clicking the Save Keyword File Icon in the Control window.

To generate a database file click on the Database Icon in the Controls window. This will bring up
the Database Generation window. Click on the Check Icon that will check the current pre-
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processor information to see if a database can be generated. If there are no errors shown, then
the database can be generated. Click on the Generate Icon to generate the database.

From the Main System window, click on the Simulation... button. Once the simulation has been
started, monitor the Simulation from the Process Monitor.

Click on the Post-Processor button to Post-Process the results of the simulation. Load the
database Carburize.DB.
State Variables
The state variable to investigate in this simulation is again the Dominant Atom variable, which is
located under the Dif tab. Click on the State Variable icon and select the variable Dominant
Atom and plot the variable as a shaded contour. The user should see the variable in the same
state as in the end of the Carburization operation. In this simulation, the total amount of carbon
holds constant but diffuses throughout the gear tooth.
10.6. Exiting DEFORMTM-2D

To exit the DEFORM-2D System, click on the Exit button in the DEFORM-2D System
window.
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11. MODELING OF QUENCHING OF A GEAR TOOTH 1

11.3. Setting Material Properties 2
11.4. Setting Object Properties 2

DEFORM-HT Labs
11. Modeling of Quenching of a Gear Tooth
Create a directory called Quench, change to that directory, type DEFORM2 and
press ENTER. The DEFORM-2D System Window will appear. Enter the
Pre-Processor to define your simulation data. Click on the Pre-Processor button.
The DEFORM-2D Pre-Processor will appear consisting of the Display
window, the Control window, and the Message window. To continue an old
problem you have to start from the last saved step in the old database. Change
the Problem ID to Quench. Go to the top menu bar and click on File. Select
Load Database and load the database Diffusion.DB. The Select Database Step
window will appear with a list of available steps to import. Select the last step
and click on the Ok button.

2) Change the Operation Name to Quench.
3) Set the Deformation to Yes and Diffusion to No.
5) Change the number of steps to 300.
7) The process duration should be set to 13500 sec.
8) The time per step should be set to 0.1 s.
9) Click on the Advanced Step Controls icon.
10) Change the maximum time change per step to 20 s and the minimum time
change per step to 0.1 s.
11) Press Ok in the Advanced Step Controls window and the Stopping Step
window.
13) Set the environment temperature to 20 C and change the convection
coefficient to 2.093.
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11.3. Setting Material Properties

The user needs to define the hardness data for the three phases in order to predict
the hardness of the gear tooth at quenching.
1) First click on the Material Properties icon in the Control window.

2) Click on the Hard. tab in the Material Properties window.
3) Set the hardness value for Austenite to 20 (Rockwell C).
4) Select the Bainite material group and set the hardness value to 30 (Rockwell
C).
5) Select the Martensite material group and set the hardness value to 55
(Rockwell C).
6) Press Ok in the Material Properties window.
11.4. Setting Object Properties

At this point the user will set the hardness calculation type to volume fraction
method.
1) Click on the Objects icon in the Controls window.

2) Click on the Properties icon.
3) Set the Hardness estimation type to Using Volume Fractions.
4) Press Ok in the Object Properties window and press Ok in the Objects
window.
5) Click on the Save Keyword icon to save the file.
Question: How is this simulation implementing the hardness model?

In the material properties there is a hardness value for each phase. The hardness for
austenite is 20, the hardness for Bainite is 30 and the hardness for martensite is 55. Using
a volume fraction weighted calculation, the composite hardness for the final product is
determined. Thus, if half of an element transforms to Bainite and the other half transforms
to Martensite, the hardness value is the volume fraction weighted average of the two
phases which gives a value of 42.5. It is important for the user to note that this simulation
in this lab does not allow the hardness in each phase to vary as a function of carbon
content. However, by changing the hardness data to a function of atom, the hardness for
each phase can vary with carbon.

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Click on the Generate Icon to generate the database.

From the System window, click on the Simulation... button. Once the simulation
has been started, monitor the Simulation from the Process Monitor.

Load the database Quench.DB.
State Variables
A state variable to investigate in this simulation is Hardness variable. Click on

the State Variable icon, click on the Mic tab, select the variable Hardness,
select the Hardness component and plot the variable as a shaded contour with
Local scaling. This gives the prediction of the hardness of the gear tooth as a
function of position. Another state variable that gives meaningful results is the
Volume Fraction variable. This shows the Austenite change to Bainite and
Martensite.
Question: What if I wanted to use Jominy curve data instead of

estimating hardness from volume fraction?
DEFORM allows the user to make use of Jominy curve data. DEFORM will
compute the cooling rate for each element and make a hardness estimate based on the
Jominy curve. The method of specifying Jominy curve data is
1) Specify hardness estimation type under Objects/Properties to Using Jominy
Curves.
2) Go to Material Properties and click the Hard tab. Select the mixture material and
make the Cooling Time a function.
3) Click on the Table Entry in the Cooling Time and enter the Cooling Time versus
Distance of the Jominy bar data.
4) Click on the Jominy Curve Data icon and enter the Hardness versus distance data.
This will fully specify the required information for the hardness estimation.
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11.8. Exiting DEFORMTM-2D

To exit the DEFORM-2D System, click on the Exit button in the DEFORM-
2D System window.
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12. GRAIN MODELING
12.1 Introduction
12.2. Load Deformation Keyword File
12.3. Specify Grain-related Material Data
12.4. Input Initial Grain Variables
12.5. Run Deformation Simulation
12.6. Prepare and Run Air-cooling Simulation
12.7. Prepare and Run Water-Quenching Simulation
12.8. Post Processing
12.9. Changing Conditions

DEFORM-HT Labs
DEFORM-HT Labs
12. Grain Modeling

12.1. Introduction
The intent of the lab is to demonstrate to the user how to use the DEFORM2D Grain Model to
simulate the grain microstructure evolution during forming and heat-treating processes.
Evolution mechanisms of static recrystallization, meta-dynamic recrystallization, dynamic

recrystallization, and grain growth are computed in the model. In each time step, based on the
time, local temperature, strain, strain rate, and evolution history, the mechanism of evolution is
first determined, and then the grain variables are computed and updated. A complete
mathematical explanation on the model is available in the Users Manual. There are a total of 16
grain variables that are used by the model and stored in the database. Recrystallization fraction
and average grain sizes are usually of the most interest to users.
Due to the complexity during deformation, the DEFORM grain model does not compute dynamic
recrystallization simultaneously. The dynamic recrystallization that would have occurred during
deformation is actually computed at the step right after the deformation. Meta-dynamic and
static recrystallizations occur during non-deforming time. This means the users will not see any
results unless the deformation simulation is followed by a non-deformation simulation (usually
heat-treatment). To simulate a complete microstructure evolution, the workpiece should be
sufficiently cooled at the end of simulation.
This lab models a simple upsetting process followed by air-cooling and water quenching. The
problem is axisymmetric and uses SI units. The workpiece material is IN718, and the die
material is steel H-13.
12.2. Load Deformation Keyword File

Start DEFORM-2D pre-processor using Problem ID GRAIN_LAB, import keyword file
UPSET.KEY. This keyword file contains all information for an upsetting forging simulation.
12.3. Specify Grain-related Material Data

Click simulation control button, and activate grain.
Go to Materials and select IN718, click grain tab. Choose "DEFORM Model " and click the
data entry button.
Activate meta-dynamic and grain growth and deactivate the other two. Input the following data
into the corresponding matrixes.
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Peak Strain:
Temp. a1 n1 m1 Q1 c1 a2
0 4.659e-3 0 0.1238 49520 0 0.83
Strain Rate Limit:

Temp. A b1 b2 Q2
0 10000 0 0 0
Meta-dynamic Recrystallization Kinetics:

Temp. a4 H4 n4 m4 Q4 Beta_m Km
0 3.794e-9 0 -1.42 -0.408 196000 0.693 1
Meta-dynamic Recrystallization Grain Size:

Temp. a7 h7 n7 m7 Q7 c7
0 4.85e+10 0 -0.41 -0.028 -240000 0
Grain Growth:
Temp. M a9 Q9
0 2 9.44e+19 467114.7
These data can be a function of temperature or strain rate. The first column of the matrix
specifies the temperatures or strain rates of the data. If the data is independent of temperature or
strain rate, the value of the first column is insignificant.
Input 300 in Temp Limit, which prohibits Grain Modeling under this temperature. Keep 0 in
Strain Retaining Coef. Click OK and exit.
12.4. Input Initial Grain Variables

Go to Objects window, select the workpiece, and click element data.
Click Grain tab. All grain variables can be defined and displayed here.
Initialize both Average Grain Size and Initial Grain Size with 100, which is in unit m. The
Initial Grain Size stands for the unrecrystallized grain size.
Display Average Grain Size and Initial Grain Size to confirm the correct initializations.
Click OK to exit.
12.5. Run Deformation Simulation

Generate the database GRAIN_LAB.DB and run the simulation.
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12.6. Prepare and Run Air-cooling Simulation

When the simulation is over, load the last step into the Pre-processor.
Go to Simulation Control window and turn off the deformation. Go to Stopping Step,
change steps by to Time, input 0.1 for Time per step. Set Number of simulation steps to
20 and Step increment to save to 5. This will model an air-cooling process of 2 seconds.
Go to Object and specify the velocity of the upper die as 0.
Go to Inter Object and move the upper die up by 5mm. Regenerate contact.
Generate the database and run the simulation.
12.7. Prepare and Run Water-Quenching Simulation

When the air cool simulation is over, load the last step of database into the Pre-processor. Now
if you go to object Element Grain, you can view current recrystallization percentage
and average grain size.
Go to Simulation Control window. In Processing Condition, change the environmental
Convection coefficients to 15 to simulate water quenching. In Stopping and step, set
Number of simulation steps to 100.
Go to Inter Object and move the lower die down by 5mm. Regenerate contact.
Generate the database and run the simulation.
12.8. Post Processing

When the simulation is over, load the database into the Post-processor. You can see the results
in State Variables. You can also use Objects Element to see all grain variables. The results
can also be Point Tracked.
12.9. Changing Conditions

It is often interesting to see how the final microstructure will deviate if the processing conditions
are changed. For example, you can modify the air-cooling duration from 2 seconds to 10 seconds
and see a very different final grain size distribution. You can also increase the coefficient a4
in the Meta-dynamic Recrystallization Kinetics to accelerate the recrystallization, etc.
(If you are interested in additional grain-related material data, load " WASPALOY[1750-
2100F(950-1150C)](Grain)" from the system material library).
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12-4
DEFORM-Heat Treatment Wizard Lab
HEAT TREATMENT WIZARD LAB
1. Starting a new problem 1
2. Set unit system 1
3. Import geometry 2
4. Generate mesh 2
5. Material definition 2
6. Workpiece initialization 2
7. Medium definition 3
8. Schedule definition 5
9. Simulation control 5
10. Submit simulation 6

DEFORM-Heat Treatment Wizard Labs
Problem Summary:
This lab will demonstrate how to use the Heat Treatment Wizard to conveniently prepare a
multiple-stage heat-treatment simulation. Phase transformation of the material (JIS S45C) will be
simulated. Multiple zones of heat-transfer coefficients are assigned to the workpiece.
1. Starting a new problem

Start a new Heat Treatment Wizard problem with problem ID QUENCH. You can do so
by clicking the New problem button and choose Heat treatment. Alternatively, you
can right click on the directory tree to create an empty directory and click Heat treatment
on the right side of the main window.
2. Set unit system

You should see a window as below, set the "Unit System" to SI. Turn on "Deformation"
and "Phase Transformation". Click "Next".
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3. Import geometry
In page Geometry, choose import from a geometry, KEY, or DB file and click Next.
Load geometry file QUENCH_PART.IGS.
4. Generate mesh
In page Mesh Generation, use 500 for unstructured mesh. Use 2 layers of structured
surface layer, set "Thickness mode" to be "ratio to object overall dimension", and 0.005
and 0.01 for thickness of layer 1 and 2, respectively. Click Next. (The structured
surface mesh helps provide better thermal solution accuracy with less computing time.)
5. Material definition
In page Material, choose Load from material library and click Next. Pick a
material with appropriate thermal data (and phase transformation data if necessary). In
this case, we use JIS-S45C(Heat Treatment) in the Steel category.
6. Workpiece initialization
In page "Workpiece initialization", for temperature, choose "Uniform" and set 900 C. For
phase volume fraction, choose "Uniform" and set 1.0, 0, and 0 for Austenite, Pearlite, and
Martensite, respectively.
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7. Medium definition
In page Media details, you will define various media and heat transfer zones associated
with them.
1) Rename the first media to air and set the default heat transfer coefficient (HTC) to
constant 0.05.
2) Add a media Water. For its "default" HTC, load data from file
"WATER_HTC1_si.DAT".
3) Add one more heat transfer zones for media Water. Click on the object boundary to
specify the start and end points of the zone. The zone is assigned to the bottom of the
workpiece as shown below. For Zone #1 HTC, load data from file "
WATER_HTC2_si.DAT".
3
Click the button "Define functions", you can view and edit the HTC as a function
temperature as shown in the dialog below.
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8. Schedule definition
In Schedule page, input a five-stage quench schedule as below. A procedure like this is
sometimes referred as "Intensive Quenching", which is designed to create a very thin
"crust" of Martensite on the part. Such a process can achieve high surface hardness with
relative low part distortion. Click Next.
9. Simulation control
In "Step Definition", the default settings are good.
In this quenching simulation, elasto-plastic deformation will be computed. Thus,

additional boundary conditions need to be specified here. To do so, you need to select a
boundary condition item and then assign it to appropriate boundary nodes or edges by
picking the start and end points. Alternatively, you can let the program generate boundary
conditions for you by clicking "Auto Gen" buttons. Make sure to double check the
boundary conditions before you proceed.
Here, we will accept automatically generated boundary conditions.
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Click "Finish" button to generate Database file and multiple operation control file.
10. Submit simulation

Exit Heat Treatment Wizard and click "Run" in the Main window, just as submitting a
regular simulation. DEFORM simulation engine will detect the multiple operation control
file and execute accordingly.
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Use Post Processor to view the simulation results.
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DEFORM-Inverse Heat Transfer Wizard Lab
INVERSE HEAT TRANSFER WIZARD LAB
2. Set unit system 1
4. Generate mesh 2
6. Initial temperature 3
7. Temperature Measurement Points 3
8. Thermal history 4
9. Heat transfer zones 5
10. Heat transfer coefficient function definition 5
12. Optimization control 7
13. Data checking 7
14. Optimization 8
15. Optimization results 8

Problem Summary:
This lab will demonstrate how to use the Inverse Heat Transfer Wizard to determine heat
transfer coefficients of between workpiece and media during a heat transfer process. Temperature
measurement data are needed. Heat transfer coefficients can be functions of temperature or time.
Multiple zones of heat-transfer coefficients are assigned to the workpiece.

Start a new Inverse Heat Transfer Wizard problem with problem ID SIMPLE_INVHEAT.
You can do so by clicking the New problem button and choose Inverse Heat.
Alternatively, you can right click on the directory tree to create an empty directory and
then click Inverse Heat on the right side of the main window.
2. Set unit system

You should see a window as below, choose English for "Unit System", and set Geometry
Type to Axisymmetric. Click "Next".
1
3. Import geometry
Import geometry file SIMPLE_INVHEAT.IGS from labs2d directory.
4. Generate mesh
surface mesh, set "Thickness mode" to be "ratio to object overall dimension", and 0.01 and
0.02 for thickness of layer 1 and 2, respectively. Click Next. (The structured surface
mesh helps provide better thermal solution accuracy with less computing time.)
In page Material, choose Create a new material and click Next. In the Material
Wizard, you only input thermal data: 0.1 for Thermal Conductivity, 0.2 for Heat
Capacity, and 0.3 for Emissivity. You dont need to save the material in library.
2
6. Initial temperature
In page Initial temperature", for workpiece choose "Uniform" and set 600 F. For
Environment, choose constant 68 F.
7. Temperature Measurement Points

In Temperature Measurement Points page, click Add button three times and input
coordinates (0.6, 1.0), (1.5, 0.5), and (0.0, 0.0) in the table for point 1, 2, and 3,
respectively. Click Apply, and you can see points in the graphical window. Click
Next.
3
8. Thermal history
In Thermal History page, load a file SIMPLE_INVHEAT_Thermal_History.DAT.
Click Apply to see the graphs. Input 10 seconds for Process End Time. Click
Next.
4
9. Heat transfer zones

In page Heat transfer zones, click Add twice. To define each heat transfer zone, you
should use the mouse to pick the start in end points on the object boundary. Pick the right
boundary to be zone #1 and top boundary to be zone #2. Leave left and bottom sides
blank because they are symmetric axes. Click "OK".
10. Heat transfer coefficient function definition

In page Heat transfer coefficient function definition (I), set heat transfer coefficient as a
function of temperature. Toggle on Initialize functions and input 4 for Number of
control points. In table Control points, input 300, 400, 500, and 600. The default
initial guess, lower and upper bounds are fine. Click OK.
5
In page Heat transfer coefficient function definition (II), all defaults are fine. Click
OK.

In Simulation Control page, use step definition Auto, and change Temperature
change per step to 5.0. Click Next.
6
12. Optimization control

In Optimization Control page, all default settings are fine, so click Next.
13. Data checking

In Data Checking page, click Check Data and then Next.
7
14. Optimization
In Optimization page, click Start. The optimization may take up to a few hours, and
you can activate the background command prompt to see program output.
After the first iteration is completed, you can see the history of the objective function on
the left. Also you can click Next to view current optimization results.
15. Optimization results

In Optimization Result page, you can view the optimal heat transfer coefficients and
compare the simulated thermal history with the measured thermal history. You can the
optimization results if necessary.
8
9
TWO STAGE TEMPERING HEAT TREATMENT LAB
2. Initialization 2
4. Generate mesh 2
6. Workpiece initialization 5
7. Medium definition 5
8. Schedule definition 8
10. Submit simulation 10
11. Post processing 11

Problem Summary:
This lab will demonstrate how to simulate a complex tempering heat treatment problem of
a steel part. This lab can also help users understand and capabilities and limitations of DEFORM-
HT's phase transformation calculation scheme.
In this lab, the problem is set up using the Heat Treatment Wizard, as multiple stages are
involved in the heat treatment. Theoretically, this type of problem can also be set up in the regular
Pre-Processor, but with less convenience and greater flexibility.

Start a new Heat Treatment Wizard problem with problem ID "Tempering". You can do
so by clicking the New problem button and choose Heat treatment. Alternatively, you
can right click on the directory tree to create an empty directory and click Heat treatment
on the right side of the main window.
1
2. Initialization
In the "Initialization" dialog, set the "Unit System" to SI, and set "Geometry Type" to
Axisymmetric. Turn on "Deformation", "Diffusion", and "Phase Transformation". Click
"Next".
3. Import geometry
Go to directory Labs/HeatTreat, and load geometry file TemperingPart.GEO.
4. Generate mesh
surface layer, set "Thickness mode" to be "ratio to object overall dimension", and 0.005
and 0.01 for thickness of layer 1 and 2, respectively. Click Next. (The structured
surface mesh helps provide better thermal solution accuracy with less computing time.)
2
In page Material, choose Import from .DB and .KEY and click Next. Import
material "Demo_Temper_Steel.KEY" from directory labs/HeatTreat.
You can click button "Advance" to view and edit the material and transformation data.
Note that this is a complex mixture material with eight constituents (phases), including
Austenite (A), Pearlit+Banite (PB), Martensite (B), Ferrite (F), Low-temp. Martensite
(LM), Temper Banite (TB), Temper Ferrite+Cementite (TFC). The transformation
kinetics between the phases include A->F, A->PB, A->TB, A->M, PB->A, M->LM, M-
>A, LM->TFC, TB->A, and TFC->A. Among these kinetics, A->F, A->PB, A->TB, M-
>LM, and LM->TFC are diffusion-controlled defined by TTT curves. A->M uses
Martensitic transformation model, and PB->A, M->A, TB->A, and TFC->A use
simplified diffusion model. In addition, A->F has an equilibrium volume fraction that
depends on carbon contents.
3
4
6. Workpiece initialization
In page "Workpiece initialization", for "Temperature", choose "Uniform" and set 20 C.
For "Atom", choose "Uniform" and input 0.2. For "Phase volume fraction", choose
"Uniform" and set 1.0 for "Pearlite + Banite", and zero for the rest.
7. Medium definition
In page Media details, you will define various media and heat transfer zones associated
with them.
1) Rename the first media to Furnace and set the default heat transfer coefficient
(HTC) to constant 0.1.
5
2) Add a media Polymer Solution. For its "default" zone, define the HTC as a function
of temperature as follows:
Temperature HTC
20 3.5
400 8.5
700 15
900 5.2
3) Add a heat transfer zone to the media Polymer Solution. Click on the workpiece
boundary to specify this zone using the "start-and-end-point" selection mode. The zone
should be on the bottom of the workpiece as shown in the graph. Define HTC as a
function of temperature as follows:
Temperature HTC
20 3.5
200 4.5
400 8.8
700 3.5
900 2.8
4) For media Polymer Solution, deactivate "Radiation". Specify the "Diffusion Surface
Reaction Rate" as a function of temperature as follows:
Temperature HTC
20 0.1
500 0.2
1000 0.6
6
3) Add one more media Air. Input 0.02 for the default HTC.
7
8. Schedule definition
In Schedule page, input a five-stage schedule as explained below.
1) One hour (3600 s) of furnace heating. The temperature of the furnace is specified as a
function of time. This function can be input by clicking the corresponding "Define" cell in
the "Advance" column.
Here, the furnace temperature function is as follows:

Time (s) Temperature
0 20
600 600
1200 880
3600 880
8
2) 10 minutes (600 s) of quenching in the polymer solution. Specify the "Atom" content to
be 0.8.
3) 30 minutes (1800 s) of tempering at 250C.
4) 30 minutes (1800 s) of tempering at 350C.
5) One hour (3600 s) cooling in the air.
In "Step Definition", change "Temp. change per step" to 2. Accept other default settings.
In this simulation, elasto-plastic deformation will be computed. Thus, additional boundary

conditions need to be specified here. To do so, you need to select a boundary condition
item and then assign it to appropriate boundary nodes or edges by picking the start and end
points. Alternatively, you can let the program generate boundary conditions for you by
clicking "Auto Gen" buttons. Make sure to double-check the boundary conditions before
you proceed.
Here, we will accept automatically generated boundary conditions.
9
Click "Finish" button to generate Database file and multiple operation control file.
10. Submit simulation

Exit Heat Treatment Wizard and click "Run" in the Main window, just as submitting a
regular simulation. DEFORM simulation engine will detect the multiple operation control
file and execute accordingly.
10
11. Post processing

Use Post Processor to view the simulation results. The temperature min-max history
should look like the lower-left graph blow:
There are a few interesting points to observe in the simulation:
1. In this problem, A->F transformation has equilibrium volume fraction that depends on
atom content. The carbon content is high near the surface due to diffusion from the
environment, therefore, very low F is formed there. In the interior, more F is formed, and
A->F transformation competes with A->PB. (This is because in our kinetics data, both are
diffusion controlled and active within the similar time-temperature range.)
2. Maximum residual stress was high after quench (~1320 MPa), and reduced after
tempering (~400 MPa).
3. After quench, M is near 0.8 on the surface. It reduced to 0.03 after tempering. Most of
M has become LM and TFC.
11

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1.

GEOMETRY MANIPULATION - XYR FORMAT

1.1. Creating a New Problem

1.2. Setting Simulation Controls

1.3. Creating a New Object

1.4. Display Manipulation

1.5. Point Selection

1.6. Other DISPLAY Window Buttons

1.7. Saving the Problem

1.8. Exiting DEFORM-2D

1. Geometry Manipulation - XYR Format

new problem using the DEFORM-2D pre-processor by clicking .

Icon Function Description

1.2. Setting Simulation Controls

1.3. Creating a New Object

In DEFORM-2D, an objects surface definition is referred to as its geometry. An objects

XYR coordinates in the table and then click on the button.

1.4. Display Manipulation

Icon Function Description

Zoom The DISPLAY window can be dynamically zoomed in

Magnify A portion of the DISPLAY window can to be magnified

corner of the zoom box and dragging the cursor to create

1.5. Point Selection

Point Selection Icons

Icon Function Description

1.6. Other DISPLAY Window Icons

Icon Function Description

Refresh Refreshes the DISPLAY window and clears the screen

View Fit Fits all objects into the DISPLAY window

View Back Reverts back to the last view used

Capture Image Captures the DISPLAY window and saves it to a file

Print Captures the DISPLAY window and sends it to the

1.7. Saving the Problem

1.8. Exiting DEFORM-2D

Exit the Pre-processor by clicking the Exit icon.

or the button. When asked whether you want to quit, click .

2.1. Creating a New Problem

2.2. Setting Simulation Controls

2.3. Creating New Objects

2.4. Saving the Problem

2.5. Exiting DEFORM-2D

2. Geometry Input - IGES Files

On a unix machine, type DEFORM2 to open DEFORM-2D. On a Windows machine, go to

problem using the DEFORM-2D Pre-processor by clicking . Click to

2.2. Setting Simulation Controls

and Geometry is set to Axisymmetric. Click the button when finished.

2.3. Creating New Objects

Use the icon to add three objects to the Object Tree.

DISPLAY window. By default, the option should be checkmarked and

Whenever a geometry is imported, it should be checked. Click the button and

the geometry to make sure it is OK.

the geometry to make sure it is OK.

2.4. Saving the Problem

2.5. Exiting DEFORM-2D

Exit the Pre-processor by clicking the Exit icon.

3.1. Creating a New Problem

3.2. Setting Simulation Controls

3.3. Creating a New Object

3.4. Saving the Problem

3.5. Exiting DEFORM-2D

3. Geometry Input - Geometry Correction

On a unix machine, type DEFORM2 to open DEFORM-2D. On a Windows machine, go to

problem using the DEFORM-2D Pre-processor by clicking . Click to